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I love my Roomba overall but the castor and wheel design is so below par its ridiculous. The wheel WILL NOT STAY IN PLACE. That means that very little gets vacuumed as the machine cant navigate properly without it. All the while the battery is wearing out for nothing and the unit cant dock so I find it dead somewhere and the carpet isn't clean. Then I have to go on a search mission just to find the wheel which isn't easy due to its size. So instead of coming home to clean carpets I waste time searching for a wheel which thankfully my dogs havn't choked on or chewed. This has to be the most obvious design flaw. The pin would be next to impossible to clean if the wheel isn't removed from the castor so I don't understand what one reviewer is talking about. The biggest downside of Roomba is the constant cleaning of the brushes etc. so if the wheel isn't supposed to be removed for cleaning, make sure it never needs cleaning or make sure the cleaning is possible without it breaking the castor pin when the wheel is removed. Just to remove the castor you have to pull it out by the wheel anyway. Thankfully the part is cheap. Relatively cheap to replace if you don't mind paying for shipping and cheap quality. I love my Roomba but this is disappointing and the fix so easy.

I am no design engineer but remodeling this wheel to make it out of the same rubber material as the left and right larger ones would make perfect sense. This material would extend the life of the wheel and improve it's use. Come on Roomba engineers.... fix an obvious (however small) problem, that we Roomba owners eventually have issues with! I have purchased over fifteen Roomba units over the years, for friends and personal use. I love the Roomba ...such a great machine, just needs tweaking.

I have the 545 and after a few times of cleaning the wheel, it began to fall out. I simply take a small piece of foil and wedge it in between the shaft and the holder. The shaft stays in place until you clean it again. The shaft needs to be removed to clean any animal hair that has wrapped around it otherwise the wheel is not free flowing. I've been doing this well over a year with great results and have not had to replace the Caster Assembly. Would be nice if they could fix this but for now I will not buy a new assembly until this no longer works. LOVE my Roomba!!!!

As many have noted, this is the weakest link in any roomba vacuum. This part needs to be redesgined *yesterday*. It will fail. I just ordered 2 in anticipation of this, and thatcost me $20 after tax and shipping. Ridiculous part for an otherwise fantastic machine.

My several-year-old Roomba 560 has a castor wheel that has never needed to be replaced. I have removed the wheel and replaced it countless times to clean the hair out of the axle (which keeps it from turning). My new 770's castor breaks when you remove the wheel so the axle pins will not stay in place and the wheel falls out freely. Is this iRobot's plan to keep me buying castors instead of being able to clean them? Either sell me a castor wheel I can clean, or design it so it won't stop turning when hair wraps around the axle! As for now, I will install some small pins to keep the wheel in place between cleanings, which is a shame that I should have to do on my NEW 770!

The ball in the caster assembly keeps falling out. After reading other reviews, I found that this is a common problem, so I ordered 2 of them instead of one. Problem with design because you have to take the ball out to remove the pet hair buildup otherwise it won't roll. By doing that, however, the plastic parts break requiring replacement. Bit of a problem, but I love my robot and would not do without it. No big deal to replace such a small part.

FYI - I just found out when I called to order some accessories today that we aren't supposed to remove the wheel from the caster assembly to clean it - we are supposed to remove the whole caster assembly itself - that will give us access to clean the wheel and what is behind it.

This was not at all clear to me from the instructions. The only reason I didn't remove the wheel was that I physically couldn't. I'm guessing that's why the plastic pins break when we do - the wheel itself isn't supposed to be removed!

I have three King Charles Cavaliers. I bought the I-robot to help with the hair issue. It rarely gets through a cleaning cycle without stopping bc the brush cage needs cleaning. Also, it seems to get hung up on electrical cords too easily. Requires a lot of time "cleaning" the device. The caster assembly wore out in three months. Wheel keeps falling out. Customer service was nice enough to replace at no charge. It's a good product. I like that it can get hard to reach areas such as under beds and dressers. Just be ware of these issues if you have pets that shed. I'm not sure this will save you time.